Intake Manifold: Service and Repair

1. Disable airbag system, then drain engine coolant.
2. On models with automatic transaxle, disconnect throttle cable from throttle body.
3. On all models, disconnect accelerator cable from throttle body.
4. On models with cruise control and anti-lock brake system (ABS), disconnect cruise control actuator electrical connector, remove four actuator attaching bolts, actuator and bracket.
5. On models with cruise control less anti-lock brake system (ABS), proceed as follows:
a. Remove cruise control actuator cover, then disconnect vacuum hose from air intake chamber.
b. Disconnect actuator connector, then cable from actuator.
c. Remove three actuator attaching bolts and actuator.
6. On all models, remove air cleaner assembly as follows:
a. Disconnect intake air temperature sensor electrical connector.
b. Disconnect accelerator cable from bracket on air cleaner cap.
c. Disconnect four air cleaner cap clips, then air hose from air pipe.
d. Disconnect air cleaner hose from throttle body, then remove air cleaner cap and element.
e. Remove three air cleaner case retaining bolts, then the case.
7. Remove alternator, then A/C compressor without disconnecting A/C lines.
8. Disconnect distributor electrical connector, then using a screwdriver separate high tension cord from ignition coil.
9. Disconnect spark plug wires from spark plugs, then remove distributor.
10. Remove engine undercovers.
11. Raise and support vehicle.
12. Remove lower crossmember attaching bolts and nuts, then the crossmember.
13. Remove front exhaust pipe as follows:
a. Disconnect oxygen sensor connector.
b. Loosen bolt, then disconnect clamp from support bracket.
c. Remove front exhaust pipe-to-catalytic converter attaching bolts and nuts.
d. Disconnect support hook on front exhaust pipe from support bracket, then remove front exhaust pipe and gaskets.
14. On California models, disconnect sub-oxygen sensor connector.
15. On all models, disconnect main oxygen sensor connector and lower vehicle.
16. Remove six manifold upper heat insulator attaching bolts and insulator.
17. Remove two bolts and nuts from catalytic converter stay.
18. Remove six exhaust manifold retaining nuts, then exhaust manifold and catalytic converter assembly.

Fig. 2 Cylinder Head Components:

19. Separate exhaust manifold and catalytic converter assembly as shown in Fig. 2.
20. Disconnect water temperature sender gauge connector, water temperature sensor connector and cold start injector time switch connector.

Fig. 3 Cooling System & Vacuum Hoses:

21. Disconnect cooling system hoses and vacuum hoses shown in Fig. 3.
22. Remove two water outlet attaching bolts, water outlet and gasket.
23. Remove two water by-pass pipe attaching bolts and nuts, water by-pass pipe and gasket.
24. Remove O-ring from water by-pass hose.
25. Disconnect throttle position sensor electrical connector and idle speed control valve connector.
26. Disconnect PCV hose, vacuum modulator vacuum hoses and vacuum switching valve vacuum hoses from throttle body.
27. Remove four throttle body attaching bolts, throttle body and gasket.
28. Remove two cold start injector pipe union bolts, four injector gaskets and injector pipe. When removing union bolts, place a shop towel under injector pipe and slowly loosen union bolt.
29. Remove two cold start injector bolts, cold start injector and gasket.
30. On California models, disconnect EGR gas temperature sensor connector.
31. On all models, remove vacuum hoses from EGR vacuum switching valve and vacuum hose from charcoal canister.
32. Loosen union nut from EGR pipe, then two EGR attaching bolts, EGR valve, vacuum modulator, vacuum hoses assembly and gasket.
33. Disconnect vacuum sensor hose and brake booster hoses from air intake chamber.
34. Disconnect two A/C vacuum hoses from air switching valve on air intake chamber.
35. Disconnect air hose from intake manifold, air hose from A/C air switching valve and two air hoses from power steering pump.
36. Disconnect engine wire clamp, then remove two bolts wire bracket and air tube.
37. Disconnect engine wire ground strap from intake manifold, then remove EGR vacuum switching valve.
38. Disconnect two wire clamps from wire brackets on top of intake manifold.
39. Disconnect wire clip from accelerator bracket, then remove two intake manifold stay attaching bolts and stay.
40. Loosen pulsation damper and two bolts holding delivery pipe to cylinder head.
41. Remove pulsation damper and disconnect fuel inlet hose from delivery pipe.
42. Remove two bolts and delivery pipe together with four injectors. Be careful not to drop injectors, when removing delivery pipe.
43. Remove right front wheel assembly, then the power steering drive belt.
44. Slightly raise engine assembly enough to remove weight from right side engine mounting assembly.
45. Disconnect connector from ground wire on right side fender apron.
46. Remove righthand engine mounting stay and disconnect power steering reservoir tank from bracket.
47. Remove right side engine mounting insulator through bolt, two nuts and insulator.
48. Lower engine, then remove three right side engine mounting bracket attaching bolts and bracket.
49. Remove spark plugs.
50. Disconnect engine wire from alternator bracket and adjusting bar.
51. Remove five timing belt cover attaching bolts, cover and two gaskets.

Fig. 4 Aligning Mark On Crankshaft Pulley & Timing Mark:

52. Turn crankshaft pulley and align its groove with timing mark ``0'' of the No. 1 timing belt cover, Fig. 4.

Fig. 5 Aligning Bearing Cap Mark:

53. Check that hole of camshaft timing pulley is aligned with timing mark of bearing cap, Fig. 5. If not turn crankshaft 360°.

Fig. 6 Timing Belt & Camshaft Pulley Matchmarks:

54. Scribe matchmarks on timing belt and camshaft timing pulley to match end of No. 1 timing belt cover as shown in Fig. 6.
55. Remove timing belt from camshaft pulley.
56. Using torque wrench adapter tool 09249-63010 and driveshaft holding tool 09278-54012 or equivalent, remove camshaft pulley bolt, plate washer and pulley.
57. Remove No. 1 idler pulley and tension spring.
58. Remove four No. 3 timing belt cover attaching bolts and cover. Support timing belt, so meshing of crankshaft timing pulley and timing belt does not shift. Be careful not to drop anything inside timing belt cover. Do not let belt come in contact with oil, water or dust.

Fig. 7 Removing Engine Hangers & Disconnecting Ground Strap:

59. Remove engine hangers attaching bolts, engine hangers and ground strap, Fig. 7.
60. Remove three alternator bracket attaching bolts, bracket and oil pressure switch.
61. Remove cylinder head cover attaching nuts, grommets, cover and gasket. Arrange grommets in correct order, so that they can be installed in their original position. This eliminates any possibility of oil leakage when original gaskets are used.
62. Before removing camshafts note that thrust clearance of the camshaft is small and camshaft must be kept level while it is being removed. If camshaft is not kept level, the portion of the cylinder head receiving the shaft thrust may crack or be damaged, causing camshaft to seize or break.

Fig. 8 Setting Knock Pin Of Intake Camshaft To 10-45:

Fig. 9 Securing Camshaft Sub-gear To Drive Gear:

Fig. 10 Exhaust Camshaft Bearing Cap Bolt Loosening Sequence:

63. Remove exhaust camshaft as follows:
a. Set knock pin of intake camshaft at 10-45° BTDC of camshaft angle, Fig. 8. This angle allows No. 2 and No. 4 cylinder lobes of the exhaust camshaft to push their valve lifters evenly.
b. Using a 6mm bolt, secure camshaft sub-gear to drive gear as shown in Fig. 9. This will remove torsional spring force of sub-gear.
c. Remove two rear bearing cap retaining bolts and bearing cap.
d. Uniformly loosen and remove six bolts on No. 1, No. 2 and No. 4 bearing caps with several passes and in sequence shown in Fig. 10. Do not remove No. 3 bearing cap bolts at this time.
e. Remove No. 1, No. 2 and No. 4 bearing caps.
f. Alternately loosen and remove No. 3 bearing cap retaining bolts. When removing No. 3 bearing cap bolts, ensure camshaft is being lifted out straight and level. If camshaft is not lifted out straight and level, retighten No. 3 bearing cap bolts. Then reverse order of above steps from step (e) to step (a) and reset knock pin of intake camshaft at 10-45° BTDC, then repeat steps from (b) to (e) once again. Do not pry on or attempt to force camshaft with a tool or other object.
g. Remove No. 3 bearing cap and remove camshaft.

Fig. 11 Setting Knock Pin Of Intake Camshaft To 80-115:

Fig. 12 Intake Camshaft Bearing Cap Bolt Loosening Sequence:

64. Remove intake camshaft as follows:
a. Set knock pin of intake camshaft at 80-115° BTDC of camshaft angle as shown in Fig. 11. This angle allows No. 1 and No. 3 cylinder cam lobes of the intake camshaft to push their lifters evenly.
b. Remove two front bearing cap and oil seal retaining bolts, then the front bearing cap and oil seal.
c. Uniformly loosen and remove bolts on No. 1, No. 3 and No. 4 bearing caps in several passes and sequence shown in Fig. 12.
d. Alternately loosen and remove No. 2 bearing cap retaining bolts. When removing No. 3 bearing cap bolts, ensure camshaft is being lifted out straight and level. If camshaft is not lifted out straight and level, retighten No. 3 bearing cap bolts. Then reverse order of above steps from step (c) to step (a) and reset knock pin of intake camshaft at 80-115° BTDC, then repeat steps from (b) and (c) once again. Do not pry on or attempt to force camshaft with a tool or other object.
e. Remove No. 2 bearing cap and camshaft.

Fig. 13 Cylinder Head Bolt Loosening Sequence:

65. Uniformly loosen and remove ten cylinder head retaining bolts in sequence shown in Fig. 13. Head warpage or cracking could result from removing bolts in the incorrect order.
66. Lift cylinder head from dowels on the cylinder block.

Fig. 14 Cylinder Head Bolt Tightening Sequence:

Fig. 15 Marking Cylinder Head Bolt:

Fig. 16 Bearing Cap Packing:

Fig. 17 Intake Camshaft Bearing Cap Bolt Tightening Sequence:

Fig. 18 Aligning Intake & Exhaust Gear Timing Marks:

Fig. 19 Exhaust Camshaft Bearing Cap Bolt Tightening Sequence:

Fig. 20 Installing Semi-Circular Plugs Into Cylinder Head:

67. Reverse procedure to install, noting the following:
a. When placing a new gasket in position on cylinder block ensure that direction is correct.
b. Apply a light coat of engine oil to threads of cylinder head bolts. Install and uniformly torque cylinder head bolts to 36 ft. lbs. in several passes in sequence shown in Fig. 14.
c. Mark cylinder head bolt with paint as shown in Fig. 15. Retighten cylinder head bolts an additional 90°. Ensure painted mark is now at a 90° angle to the front.
d. Install spark plug tubes and torque to specifications.
e. Apply multi-purpose grease to thrust portion of intake camshaft and place camshaft at 80-115° BTDC of camshaft angle on cylinder head.
f. Apply seal packing to No. 1 bearing cap as shown in Fig. 16, then install bearing caps in their proper locations. Apply a light coat of engine oil to bearing cap retaining bolts and torque to 14 ft. lbs. in several passes in sequence shown in Fig. 17.
g. Apply multi-purpose grease to new oil seal lip, then using seal installation tool No. 09223-46011 or equivalent, tap in oil seal.
h. Set knock pin of intake camshaft at 10-45° BTDC of camshaft angle.
i. Apply multi-purpose grease to thrust portion of exhaust camshaft, then engage exhaust camshaft gear to intake camshaft gear by matching timing marks on each gear as shown in Fig. 18. Roll down exhaust camshaft onto bearing journals while engaging gears with each other.
j. Turn intake camshaft clockwise or counterclockwise a little at a time until exhaust camshaft sits in bearing journals evenly without rocking camshaft on bearing journals. It is very important to replace camshaft in bearing journals evenly while tightening bearing caps.
k. Install bearing caps in their proper position, then apply a light coat of engine oil to bearing cap retaining bolts. Install and uniformly torque ten bearing cap bolts to 14 ft. lbs. in several passes, in sequence shown in Fig. 19.
l. Remove service bolt holding sub-gear and main gear, then check valve clearance adjust clearance if necessary.
m. Apply seal packing to semi-circular plugs and install them into cylinder head as shown in Fig. 20.
n. Rearm airbag system, refer to Air Bags and Seat Belts/Air Bags (Supplemental Restraint Systems)/Service and Repair.